Hot Tub Cover

ABSTRACT

One example of this application provides the only portable hard cover (hot tub cover) on the market. One example of this application provides 2 caps per molding (instead of one cap). These are big advantages for consumer and reducing manufacturing cost. Different variations have been presented here, as well.

BACKGROUND OF THE INVENTION

One embodiment of this invention provides a method for manufacturing, and the corresponding product, for a hot tub cover. The rotational molding process has been used in the prior art, for the manufacturing process, resulting in one cap per molding. However, in one embodiment of this invention, as shown here, we get 2 caps per molding (instead of one cap), resulting in more efficient way of molding and manufacturing, less expensive manufacturing, and less expensive hot tub cover, which is a big advantage.

One embodiment of this invention provides the only portable hard cover (hot tub cover) on the market. The hard cover is generally more protective as a cover for the hot tub, than a conventional soft cover. Being portable makes it easier to move around, and also, makes it more versatile to fit different hot tubs from different manufacturers, effectively, making it less expensive to manufacture, due to the economy of scale and a larger number of sales and production.

The following patents represent some of the prior art: Nos. 4,857,374; 6,112,340; 6,859,952; 5,974,599; 6,634,036; and 6,842,917.

SUMMARY OF THE INVENTION

One embodiment of this invention provides the only portable hard cover (hot tub cover) on the market. One embodiment of this invention provides 2 caps per molding (instead of one cap). These are big advantages for consumer and reducing manufacturing costs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows one embodiment of the invention, with a portable hard cover.

FIG. 2 shows one embodiment of the invention, with a portable hard cover, from side view, internal.

FIG. 3 shows one embodiment of the invention, with a portable hard cover, from side view, with the cover in the open position.

FIG. 4 shows one embodiment of the invention, with a portable hard cover, with a cross section close-up view.

FIG. 5 shows a spa with a portable cover lifter (not permanently attached) and a soft vinyl cover. (In one embodiment, we are using a lifting system just like the one shown here.)

FIG. 6 shows a spa with a permanent cover lifter attached, with a soft vinyl cover.

FIG. 7 shows an example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

FIG. 8 shows another example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

DETAILED EMBODIMENTS OF THE INVENTION

There are a lot of patents and prior art/products in the market for hot tub covers. However, we present here the only portable hard cover (hot tub cover) in the market, with 2 caps per molding (instead of one cap), during our manufacturing process.

In one embodiment, we use a conventional cover lifter mechanical system for removing hot tub covers, as shown in the figures, as an example, e.g. using a motor, chain, pulley, cable, lever, rod, railing, or a similar mechanism.

In one embodiment, we present a rotationally-molded hot tub cover with single-walled construction, which allows for a much easier method of construction and saves a lot of money for consumers. A double-walled cover completely encapsulates the foam, whereas we are basically making a “cap” that goes over the top of the foam, to protect it from the elements. With a single-walled construction, we can more efficiently mold and assemble the cover, for cost savings. In summary, we have a rotationally-molded cap with a foam core that is covered with a waterproof material, to keep it from absorbing water. These are mechanically attached to the inside of the roto-molded cap.

There has never been a rotationally-molded hard cover that can be fitted to spas after the SPA has already been manufactured, or in other words, sold on the aftermarket. The reason is that, in the past, these covers have been manufactured specific to a spa model that they were made for, and actually, they were attached to, at the factory. One either buys a hot tub with the integrated hard cover on it (that it was designed for, at the time of the purchase), or one can never get one later.

In one embodiment, our product does not mechanically attach, or require any permanent moldings or brackets on the tub, and therefore, it can be put on any tub. A typical prior art product (e.g. shown in FIGS. 5-8) has a doubled-wall, rotationally molded cover, with the permanent attachment that must be done at the factory.

In one embodiment, our rotationally-molded hard cover is single-walled, has a cover lifter attachment (similar to the other prior art spas), but it is the only hard cover with a portable cover system in the market. Our lift system (that is incorporated as a part of our cover) is not permanently attached, and therefore, it can fit on any spa. This gives us the ability to sell hard covers to people who already have purchased hot tubs and want a cover or a new/replacement cover. The other hard covers on the market cannot do this. Only soft vinyl covers have been able to accomplish this in the past.

Additionally, the single-walled construction is a superior method of manufacturing, in that it reduces manufacturing costs, making the product more affordable. The double-walled hard covers cost much more to manufacture.

Note that there are several companies that advertise “hard” covers (as opposed to a thin plastic, bubble wrap type cover), but they are just the vinyl covered styrene covers (i.e. soft covers).

Another way to describe the uniqueness of the cover is that it is the only portable hard cover, not just because it does not permanently attach, but also, because with the other hard covers, the bottom is shaped in such a way that they are form-fitted just for that model of spa. However, our cover, having a soft bottom (due to the fact that it is not doubled-walled) will conform to almost any hot tub that has roughly the same overall length and width dimensions, making it very flexible and versatile.

Here are some of the prior art shown in the figures, for comparison: FIG. 5 shows a spa with a portable cover lifter (not permanently attached) and a soft vinyl cover. (In one embodiment, we are using a lifting system just like the one shown here.) FIG. 6 shows a spa with a permanent cover lifter attached, with a soft vinyl cover. FIG. 7 shows an example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter. FIG. 8 shows another example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

FIG. 1 shows one embodiment of the invention, with a portable hard cover (e.g. integrated hard cover and cover lifter). Here are the items/features shown in the figure:

110: Hard Cover

112: Ring, Strap, or hinge

114: Axel, center rod

116: Arm to Axel fastener

120, 121: Arm brackets

122, 123: cover pieces

130: Base support with paddles (that go under the hot tub, for example). In that configuration, the but tub weight supports rotational moment from the arm brackets, due to the weight of cover, when in open position.

132: arm bracket, pivoting on the base support

134: Pin stopper(s), for example, for limiting the movement of the arm bracket beyond the allowed open (or closed) position(s). One or more pins can be used optionally for open or closed position(s).

140: cover flips open

142: arm brackets rotate back

FIG. 2 shows one embodiment of the invention, with a portable hard cover, from side view, internal. Here are the items/features shown in the figure:

210: Hard Cover, e.g., polyethylene skin (e.g., ⅛ inch thick)

214: Axel, center rod

220: Arm bracket

222, 223: filler material, e.g., Sealed foams

224, 225: Flaps (e.g. vinyl), for example, riveted inside poly skin, covering the side of the cover pieces.

230: Mounting plate with paddle.

232: arm bracket, pivoting on the mounting plate

234: Pin stopper(s), for example, for limiting the movement of the arm bracket beyond the allowed open (or closed) position(s).

FIG. 3 shows one embodiment of the invention, with a portable hard cover, from side view, with the cover in the open position. Here are the items/features shown in the figure:

300: hot tub side view

301: bottom of hot tub

314: Axel, center rod

320: Arm bracket

322, 323: hard cover pieces

330: Mounting plate with paddle (that goes under hot tub, for example). In this configuration, the but tub weight supports rotational moment from the arm brackets, due to the weight of cover, when in open position.

332: arm bracket, pivoting on the base support

334: Pin stopper(s), for example, for limiting the movement of the arm bracket beyond the allowed open (or closed) position(s).

342: arm brackets rotate back, for hot tub cover to get in the open position

FIG. 4 shows one embodiment of the invention, with a portable hard cover, with a cross section close-up view. Here are the items/features shown in the figure:

410: Hard Cover, e.g. Single-walled roto-molded polyethylene

422: Filler material, e.g., polystyrene, polyurethane, expanded polystyrene, polyethylene foam, or similar material

424: Flap (e.g. vinyl or rubber), or similar material

426: Attachment screws, rivets, and/or adhesive glue

428: Protective material, e.g., water resistant material.

The hot tub area can be of any size (as one embodiment), to accommodate one or more individuals, however, at a typical, lower range/dimensions, it can be 4′ to 10′ in length, 29″ to 6′ in height, and 4′ to 9′ in width. However, the sizes mentioned here are typical ranges for some embodiments, as examples, and the invention covers any size, big or small.

The material of our system may comprise one or more of the following: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material (embedded with e.g. water pipes or heater wires), hollow material, or reinforced material (e.g. with metal bar, fabric, or mesh).

The shape of our tub may be one or more of the following: oval, rectangle, square, straight, curved, circular, multiple cross sections, or single cross section, comprising one or more of the following: multiple jets, single jet, multiple flows, single flow, with flow meter, cleaning/ filtering mechanism, light, underwater light, dancing light monitored by a computer, with music synchronization, multiple lights, gradual changing lights, rainbow lights, lasers, or any combination of the above.

Any variations of the teachings above are also meant to be covered and protected by this current application. 

1. A portable hot tub cover, said portable hot tub cover comprising: one or more caps, wherein each pair of said one or more caps is manufactured from same molding process; a hard cover, wherein said hard cover covers a hot tub in a closed position; a cover lifter, wherein said cover lifter moves said hard cover between said closed position and an open position; an attachment device, wherein said attachment device attaches said portable hot tub cover to said hot tub's body.
 2. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more motors.
 3. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more stopping pins.
 4. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more rods or arms.
 5. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more brackets.
 6. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more hinges.
 7. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more screws.
 8. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more sealed sections.
 9. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more sealed foam sections.
 10. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more mounting plates.
 11. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more paddles.
 12. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more flaps.
 13. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more flaps, attached inside skin.
 14. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more polyethylene skin sections.
 15. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more rivets.
 16. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more polystyrene, polyethylene, polyurethane, or expanded polystyrene foam sections, pieces, volumes, or containers.
 17. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more single-walled roto-molded sections.
 18. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more attachment screws, rivets, or devices.
 19. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising: one or more water-resistant cover sections.
 20. The portable hot tub cover as recited in claim 1, wherein said portable hot tub cover further comprising one or more of the following material: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material with pipes or heater wires, hollow material, or reinforced material with metal bar, fabric, or mesh. 